Micro camera module with discrete manual focal positions

ABSTRACT

A novel micro camera module that is manually adjustable between a close-up mode and an infinite mode includes a lens assembly adjustably mounted within a sleeve that is adjustably mounted into a housing. In a particular embodiment the sleeve includes a channel (cam groove) that is engaged by a plurality of pins fixed to the housing. Further, a biasing member is disposed between the sleeve and the housing such that an upward force will enable the pins to firmly engage the lower portion of the channel. In a more particular embodiment, the channel defines two detents that secure the sleeve into predetermined positions with respect to the housing. In an even more particular embodiment, the channel is sloped such that upon rotation of the sleeve, the distance between the lens assembly and an image capture device is changed. In another particular embodiment, the camera module includes an electrical mode detecting switch that is indicative of the position of the camera module.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to cameras, and more particularly tovery small electronic camera modules. Even more particularly, theinvention relates to a device and method for manually adjusting thefocal field in small electronic camera modules.

2. Description of the Background Art

Cameras in general, and digital camera modules in particular are wellknown. Digital cameras commonly incorporate means for adjusting thefocal field in order to allow a user to take sharp photos of close upobjects, such as business cards or bar codes, as well as distantobjects, such as landscapes or people.

In some cameras, the focal field is continuously adjustable over apredefined range. For example, the lens is mounted to a guide so that itcan be displaced along the optical axis by an electrical or mechanicaldrive.

While continuously adjustable lens mechanisms facilitate precise focusat virtually any focal distance in the range, their complexityintroduces a variety of disadvantages. One disadvantage is thatelectrical drive units require power, which shortens battery life.Another disadvantage is the increased number of parts and requiredassembly time, both of which contribute to the overall cost of thecamera. The complexity also increases possible sources of failure and,therefore, results in a decreased reliability for the camera. Yetanother disadvantage is that the complexity of the device increases theoverall size of the camera.

In mid to lower quality cameras, many of these disadvantages can be atleast partially alleviated by replacing the continuously adjustable lensmechanism with a lens mechanism that can be manually transitionedbetween a plurality of discrete focal positions. Because the lens ismoved manually by the user between the various focal positions, thedrive motor, linkages, etc. are unnecessary. Further, providing aplurality of discrete focal positions is beneficial, because iteliminates the need to focus the lens for each picture. Thus, a user cantake average quality images with minimal effort and experience. Indeed,many digital images that are taken are relatively disposable and do notrequire a high quality image. For example, taking a picture of a phonenumber or an address on a business card does not require a very highquality photo, as long as the letters and/or numbers are legible.

Despite the advantages provided by the multiple discrete position,manually operated focus mechanism, this type of mechanism has not beensuccessfully implemented in miniature camera modules, such as cameramodules now incorporated into cellular telephones, hand-held personaldigital assistants (PDAs), and the like. Problems arise due to theextremely small size of such camera modules. For example, the componentsof miniature camera modules are many times smaller than a user's fingerand are, therefore, difficult to manipulate. Further, the smallcomponents are fragile, and can be easily broken when being directlymanipulated by a user. Further, the camera modules should be able to bemounted directly on a circuit board of the main device (cell phone, PDA,etc.), therefore access to the module is somewhat limited. Yet anotherproblem is that it would be difficult to see what position the smalllens is in at any given time. Yet another problem is that the cameramodules must compete with the host device for allocated space, so focusmechanisms that require extra space would be considered a disadvantage.For any one or more of these reasons, or other reasons, known miniaturecamera modules do not include user adjustable focus mechanisms, or atleast do not include such modules that do not suffer from one or more ofthe above described disadvantages.

What is needed, therefore, is a miniature camera module, with a useradjustable focus mechanism, that is more compact. What is also needed isa miniature camera module, with a user adjustable focus mechanism, thatrequires fewer components to function. What is also needed is aminiature camera module, with a user adjustable focus mechanism, thatminimizes points of possible failure. What is also needed is a miniaturecamera module, with a user adjustable focus mechanism, that requires ashorter assembly time and is less expensive to manufacture. What is alsoneeded is a miniature camera module, with a user adjustable focusmechanism that is easy for a user to manipulate manually. What is alsoneeded is a miniature camera module, with a user adjustable focusmechanism, that provides clear indicia of the current focal position ofthe lens.

SUMMARY

The present invention overcomes the problems associated with the priorart by providing a camera module that can be manually switched between aplurality of discrete focal positions. The camera module is verycompact, yet facilitates user adjustment of the focal distance.

The camera module includes a housing, a lens assembly, and a carrier.The carrier includes a first focusing feature for adjustably engagingthe lens assembly and a second focusing feature for adjustably engagingthe housing. In the particular embodiment shown, the carrier is a sleeveformed from a substantially cylindrical shell that includes an innerwall, an outer wall, a top surface, and a lower surface. The innerportion of the sleeve includes a portion of the first focusing feature(e.g., threads, ramps, channels, etc.), and the outer wall of the sleevedefines the second focusing feature. In the specific example shown, thesecond focusing feature is a sloped channel that is engaged by a pinfixed to the housing. The channel extends from the lower portion of thesleeve to and through the upper surface of the sleeve such that thechannel does not include an upper boundary. The channel defines therotational limits of the sleeve and includes at least two detents thatdefine different focal positions. In the particular embodimentdescribed, the detents are spaced apart depressions formed in thechannel that each provide a discrete, stable resting position for anassociated engaging pin. The channel includes an intermediate portionthat is relatively higher than the depressions, so that the pin is urgedtoward on of the depressions or the other.

The example housing shown includes a substantially rectangular base withside walls extending upwardly therefrom. A portion of the side wallsform legs extending upwardly from the corners of the base. Two of fourlegs include apertures through which retaining pins pass to engage thechannel of the sleeve. The two legs that receive pins are positionednear opposite corners of the base. The inner portions of the legs arerounded to match the contour of the cylindrical sleeve. Forming legsnear the corners of the base contributes to a reduction in the size ofthe camera module such that the width of the housing base can be assmall as the outer diameter of the sleeve.

In the example embodiment shown, a biasing member is disposed betweenthe sleeve and the housing. The biasing member is a resilient, taperedring. The bottom portion of the sleeve is tapered so as to have asimilar contour to the inner portion of the biasing member. Optionally,the biasing member is an o-ring and the bottom of the sleeve defines aseat for the o-ring.

The housing is mounted to a substrate over an image capture device alsomounted on the substrate. The example housing shown is mounted via aplurality of posts extending from the bottom of the base of the housing.The posts are fixed within apertures formed in the substrate for thatpurpose. An optional switch (mechanical, optical, magnetic, etc.) isalso mounted to the substrate. The switch engages a portion of thesleeve and generates a signal indicative of the sleeve's rotationalposition. A portion of the housing surrounds the switch to protect itfrom accidental impact.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described with reference to the followingdrawings, wherein like reference numbers denote substantially similarelements:

FIG. 1 is a perspective view of a camera module in a first discretefocal position;

FIG. 2 is a perspective view of the camera module of FIG. 1 in seconddiscrete focal position;

FIG. 3 is an exploded view of the camera module of FIG. 1;

FIG. 4 is a perspective view of a lens assembly of FIG. 2 within asleeve of FIG. 2;

FIG. 5 is a side view of the sleeve of FIG. 4;

FIG. 6 is a cross-sectional view of a biasing member of FIG. 3;

FIG. 7 is a partially exploded view of a manual adjustment device forengaging the sleeve of FIG. 4;

FIG. 8A is a top plan view of the camera module of FIG. 2;

FIG. 8B is a top plan view of an alternate camera module;

FIG. 9A is a cross-sectional view of the camera module of FIG. 8A takenalong line A-A of FIG. 8A;

FIG. 9B is a cross-sectional view of the camera module of FIG. 8B takenalong line A-A of FIG. 8;

FIG. 10 is a flow chart summarizing a method for assembling a cameramodule according to one aspect of the present invention;

FIG. 11 is a flow chart summarizing a method for mounting a carrierwithin a housing;

FIG. 12 is a flow chart summarizing a method for adjustably mounting alens assembly to a carrier; and

FIG. 13 is a flow chart summarizing a method for focusing a lensassembly.

DETAILED DESCRIPTION

The present invention overcomes the problems associated with the priorart, by providing a micro camera module with a plurality of discretemanual focal positions. In the following description, numerous specificdetails are set forth (e.g., particular lens assemblies, particularconstruction materials, etc.,) in order to provide a thoroughunderstanding of the invention. Those skilled in the art will recognize,however, that the invention may be practiced apart from these specificdetails. In other instances, details of well known electronicmanufacturing and assembly practices and components have been omitted,so as not to unnecessarily obscure the present invention.

FIGS. 1 and 2 show an assembled camera module 200 in first and seconddiscrete focal positions, respectively. In this particular embodiment,camera module 200 includes a close focal position and an infinite focalposition. In the first focal position, camera module 200 focuses onimages that are roughly within a few inches to a foot or so of cameramodule 200. This is necessary when taking photos of relatively smallobjects (e.g., business cards, bar codes, etc.) or a user taking a photoof their own face at arms length. In the infinite focal position cameramodule 200 focuses on objects that are farther from camera module 200.For example, images of a landscape or of a subject several yards awaywould be in focus at the infinite position. It should be noted thatalthough the example embodiment is shown with only two discrete focalpositions, the invention is not so limited. Indeed, alternateembodiments of the invention can include three or more discrete focalpositions.

Camera module 200 is switched between the first and second focalpositions manually. Therefore, camera module 200 does not require anyautomated drive means, thus, making it even more compact than moduleswith alternative drive means. Camera module 200 can be moved between thefirst and second focal positions either directly by a users finger orvia a simple adjustment device 700 (FIG. 7).

Although camera module 200 can be incorporated into a consumer cameraproduct, it is expected that camera module 200 will be more commonlyincorporated into consumer electronic devices having alternate primaryfunctions. For example, camera module will provide a significantadvantage over the prior art in devices including, but not limited to,mobile telephones, personal digital assistants, audio players, and othermultimedia and/or communications devices. In such devices, camera module200 competes for space with the primary components of the host device.Therefore, the compact size of camera module 200 in combination with theability to adjust focus is very advantageous.

FIG. 3 is an exploded view showing camera module 200 to include cameraelectronics 202, a housing 204, a sleeve 206, and a lens assembly 208.Camera module 200 further includes a biasing member 210 disposed betweensleeve 206 and housing 204.

Camera electronics 202 includes a substrate 212 with an image capturedevice 214 and a focal position indicator switch 216 mounted thereon.Image capture device 214 includes a sensor array 218 formed on anintegrated circuit chip and disposed substantially perpendicular to anoptical axis (y). Indicator switch 216 includes a mechanical rocker 220that is actuated by a portion of sleeve 206, as will be described ingreater detail below. Depending on the position of rocker 220, indicatorswitch 216 provides an electrical signal indicative of one of the twofocal modes (close and infinite). The electrical signal is used toprovide a user with an indication of the current focal position via auser display device (e.g., LCD, indicator light, etc.). It should beunderstood that substrate 212 can have additional circuitry mountedthereon, but such circuitry is not particularly germane to the presentinvention and, therefore, is not shown. Substrate 212 also defines aplurality of apertures 222 (only 4 of 6 visible in FIG. 3) thatfacilitate the mounting of housing 204 to substrate 212.

Housing 204 provides structural support and a means for mounting andaligning the other elements of camera module 200. In this particularembodiment, housing 210 includes a substantially rectangular base 224with walls 226 extending upwardly therefrom. At one end of housing 204walls 226 partially surround indicator switch 246 so as to provideprotection against accidental impact. At the other end of housing 204walls 226 form four sleeve support legs 228 that have rounded innersurfaces 230 contoured to the outer surface of sleeve 206 such thatsleeve 208 is constrained to rotate about the optical axis (y). Two ofthe four support legs 228 include apertures 232 that receive and supportpins 234, which slidably engage sleeve 206 to retain sleeve 206 inhousing 204 while allowing limited rotation of sleeve 206.

Providing support legs 228 at the corners of housing 204 provides a sizeadvantage. In particular, because side walls 226 need not extendcompletely around sleeve 206, the width of housing 204 need not exceedthe diameter of sleeve 206.

Housing base 224 defines an aperture 236 through which lens assembly 208focuses images on image capture device 214. A channel 238 aroundaperture 236 provides a seat for biasing member 210, which in thisparticular embodiment is a resilient ring.

Housing 204 also includes a plurality of posts 239 that each engage arespective one of apertures 222 through substrate 212. Posts 239 andapertures 222 are positioned to properly align the center of sensorarray 218 with optical axis (y). Once posts 239 are positioned throughapertures 222, they are fixed to substrate 212 via adhesive, thermalwelds, fasteners, or any other suitable means.

Sleeve 206 functions as a carrier for lens assembly 208 and provides twoseparate focusing features. In this particular embodiment, sleeve 206 isshaped substantially as a cylindrical shell and includes an inner threadset 240, a plurality of manipulation channels 242, two focus adjustmentchannels 244, and a switch engaging portion 246.

Thread set 240 functions as the first focusing feature. Thread set 240is formed on the inner wall of sleeve 206 to accept a complementarythread set 248 of lens assembly 208. The mated thread sets 240, 248provide a means for fine vertical adjustment between sleeve 208 and lensassembly 202 to facilitate factory focus of lens assembly 208 withrespect to image capture device 214. As lens assembly 208 is rotatedwithin sleeve 206, lens assembly moves along optical axis (y). Once lensassembly 208 is properly positioned within sleeve 206 (focused), lensassembly 208 is fixed in position with respect to sleeve 206 with, forexample, an adhesive or a thermal weld.

Channels 244 in combination with pins 234 provide the second (useradjustable) focus feature. Biasing member 210 exerts an upward force onsleeve 206 when sleeve 206 is positioned within housing 204. This upwardforce biases the lower portion of focus adjustment channels 244 againstpins 234, thereby maintaining sleeve 206 in the proper vertical positionwith respect to image capture device 218. Further, channels 244 definesthe range through which sleeve 206 can rotate. The structure andfunction of channels 244 is explained in greater detail with referenceto FIGS. 4-5 below.

It should be noted that the invention is not limited to the particularstructures used to provide the first and second focusing features. Forexample, complementary thread sets 240 and 248 can be replaced withother adjustment structures including, but not limited to, complementaryramps and pin/groove structures. Similarly, alternate means for defininga plurality of discrete focus positions including, but not limited to,stepped ramps and saw tooth structures can be substituted for theexample of the second focus feature described.

Manipulation channels 242 provide means for engaging and rotating sleeve206 within housing 204 after camera module 200 is assembled, as will bediscussed in greater detail below with reference to FIG. 7. As sleeve206 is rotated, switch engaging potion 246 moves rocker 220 of indicatorswitch 216 back and forth between the two previously described switchposition. It should be understood that alternate switches/indicators canbe substituted for switch 216. For example, in embodiments where thesecond focus feature includes three or more discrete focus positions, amultiple switch, a slider switch, or any other means for determining theposition of sleeve 206 can be substituted for switch 216.

FIG. 4 is a perspective view of lens assembly 208 disposed within sleeve206. Those skilled in the art will recognize that lens assembly 208 willinclude one or more lenses and other components (e.g., infrared filters,etc.), which are required to focus a clear optical image on imagecapture device 236. The particular optical components of lens assembly208 will vary according to application, and are not particularlyrelevant to the present invention. As described above, lens assembly 208includes a set of threads 248 (shown in FIG. 3), that mate with acomplementary set of threads 240 inside sleeve 206, such that lensassembly 208 can be screwed into and out of sleeve 206. Rotating lensassembly 208 within sleeve 206 will cause lens assembly 208 to move upor down (along the optical axis (y)) within sleeve 206, depending on thedirection of rotation, thereby facilitating the factory focusing ofmodule 200. Lens assembly 208 defines a raised portion 250 that enableslens assembly 208 to be engaged and rotated into focus by automatedequipment during assembly. Note that the factory focus procedure isperformed after lens assembly 208 and sleeve 206 are seated in housing204. In this particular embodiment, lens assembly 202 is designed to bethreaded almost entirely into sleeve 206, thereby decreasing the overallheight of camera module 200. Note that after lens assembly 208 isfactory focused within sleeve 206, it is fixed in position within sleeve208 by some suitable means (e.g., adhesive, thermal weld, etc.).

FIG. 5 is a side elevational view of sleeve 206 showing a tapered lowerportion 252 that engages biasing member 210, which maintains an upwardforce on sleeve 206, as will be explained in greater detail withreference to FIG. 6 below. The upward force urges the lower surface ofchannel 244 against pins 234 (FIG. 3).

Channel 244 is sloped such that upon rotation, sleeve 206 will move upor down in the y direction, depending on the direction that sleeve 108is turned (a typical range is approximately 0.15 mm to 0.3 mm.,depending on the particular design of lens assembly 208). The change iny direction changes the distance between lens assembly 208 and imagecapture device 236, thereby changing the focal field.

Note that channel 244 defines two discrete, stable focal positions. Inparticular, channel 244 includes a lower detent 254 and an upper detent256, corresponding to the close and infinite focal positions,respectively. In this particular embodiment detents 254 and 256 includespaced apart portions 254, 256 of channel 244 separated by anintermediate portion 258 that is relatively higher than the spaced apartportions 254, 256. The force exerted by biasing member 210 allows smoothrotation of sleeve 206, yet is sufficient to secure sleeve 206 intoeither of the stable focal position when pins 224 pass over the apex ofintermediate portion 258. Further, detents 254 and 256 define relativelysharp drops in channel 244 so as to provide a “click”, which indicatesto the user that sleeve 206 is secured into a stable focal position.

The degree in which sleeve 206 can rotate depends on the length ofchannel 230. In this particular embodiment, sleeve 206 can rotateapproximately forty degrees about the y-axis. This is sufficient tochange the distance between image capturing device 236 and lens assembly202 from approximately 0.15 mm to 0.30 mm. It should be understood,however, that more or less displacement along the optical axis (y) canbe provided with a greater or lesser angle of rotation, depending on theslope of channel 244. Additionally, channel 244 can include more thantwo detents, in order to provide three or more discrete, stable focalpositions. Finally, although this particular embodiment of the inventionemploys two of channels 244, it should be understood that alternateembodiments can include 1, 3, 4, or more of channels 244.

Traditionally, cam-type channels are enclosed by all sides. For example,in U.S. Pat. No. 6,426,839 B2, issued to Dou et al, a particularembodiment discloses a channel that defines an upper surface, a lowersurface, and two end surfaces. Channel 244 includes a lower surface andtwo side surfaces, and no upper surface. Because channel 244 does notinclude an upper surface, it can be manufactured and assembled moreefficiently. For example, it is easier to remove sleeve 206 from a mold,because channel 244 includes an open top. In particular, channel 244extends from a lower portion of sleeve 206 to and through the uppersurface of sleeve 206.

FIG. 6 shows a cross-sectional view of biasing member 210. In thisparticular embodiment, biasing member 210 is a tapered ring, with anupper inside diameter that is greater than its lower inside diameter.Biasing member 210 is composed of acetal copolymer, which is asemi-flexible material that allows biasing member 210 to be stretchedoutwardly without surpassing it's elastic limit. The lower taperedportion 252 (FIG. 5) of sleeve 206 is contoured similar to the innersurface of biasing member 210. Therefore, when sleeve 206 is rotatedsuch that tapered portion 252 is pushed down into biasing member 210,biasing member 210 is stretched outward rather than compressed. Whenstretched by tapered portion 252 of sleeve 206, biasing member 210exerts an inward restoring force. The inward restoring force exertedbetween the inclined surfaces of biasing member 210 and tapered portion252 of sleeve 206 causes an upward force on sleeve 206, which keeps thebottom surfaces of channels 244 pressed against pins 234.

FIG. 7 shows a perspective view of an annular, manual adjustment device700 aligned to engage manipulation channels 242 of sleeve 206. In thisparticular embodiment, manual adjustment device 700 includes twodownwardly extending engagement arms 702 that fit firmly intocorresponding channels 242 of sleeve 206. Manual adjustment device 700further includes an outer portion 704 that has a plurality small groovesthat facilitate frictional engagement by a user's finger. Optionally,manual adjustment device 700 includes a lever 706 that also facilitatesrotation of adjustment device 700 about the optical axis (y).

Adjustment device 700 engages sleeve 206 through an opening in a housing(not shown) of an electronic device (not shown) in which camera module200 is mounted. In addition to providing a means for rotating sleeve206, adjustment device 700 masks the opening in the housing of theelectronic device, thereby relaxing the required tolerances betweencamera module 200 and the electronic device. Note that the particularshape and size of adjustment device 700 is not critical, as long asadjustment device 700 provides a means for manually rotating sleeve 206.

FIG. 8 is a top plan view of assembled camera module 200. Note that noneof the components of camera module 200 extend beyond it's footprint,which has substantially the same area dimensions as substrate 212. Notealso that the diameter of sleeve 206 (which is approximately 10.0 mm) isthe same as the width of substrate 212 and the footprint of housing 204.Further, lever 246 does not extend beyond wall 226. Indeed, an alternateembodiment, switch 216 and lever 246 are omitted, and neither the lengthnor the width of the alternate camera module exceed the diameter ofsleeve 206. The combination of design features that contribute to thereduced dimensions of camera module 200 is considered to provide animportant advantage.

FIG. 9A is a cross-sectional view of camera module 200 taken along lineA-A of FIG. 8A. Most of the components shown in FIG. 9A have beenpreviously shown and described with reference to other figures of thedrawings. However, the view of FIG. 9A provides additional clarificationwith respect to the interrelationship of the various components ofassembled camera module 200. Additionally, FIG. 9A shows a transparentprotective cover 902 that protects image capture device 214 fromparticulate matter that may be generated during the mounting andfocusing of lens assembly 208 and/or sleeve 206.

FIG. 8B and FIG. 9B show an alternate camera module 200B. Most of thecomponents of camera module 200B are similar to corresponding componentsof camera module 200. However, there are some structural and functionaldifferences.

One difference between camera module 200A and camera module 200B is thatswitch 216 is omitted. As a result, the over all size of camera module200B is significantly reduced. Note that both the length and width ofcamera module 200B are only slightly larger than the outer diameter ofsleeve 206.

Another difference between camera modules 200A and 200B is that wall226B extends completely around sleeve 206B instead of forming legs 228(FIG. 8A). The continuous nature of wall 226B provides additionalstructural support, but slightly increases the overall dimensions ofcamera module 200B. In particular, note that the width of camera module8A is the same as the diameter of sleeve 206, whereas the width ofcamera module 200B is slightly larger than the diameter of sleeve 206B.

Walls 226B also extend higher than sleeve 206B and lens assembly 208,even when sleeve 206B and lens assembly 208 are in their highest focalposition. This feature provides an advantage in that walls 226B preventother structures from exerting undesirable forces on lens assembly 208and/or sleeve 206B. For example, if a protective cover or the housing ofa host device (neither shown) are positioned above camera module 200B,such structures are physically isolated from lens assembly 208 andsleeve 206B by walls 226B. Therefore, such structures are prevented fromtilting or otherwise adversely affecting the focal position of lensassembly 208.

Yet another difference is that alternate camera module 200B is thatalternate sleeve 206B includes four channels 244 which are each engagedby a respective one of four pins 234. In the embodiment shown, each ofchannels 244 is substantially identical. However, it should beunderstood that it is not necessary for all four of channels 244 toinclude a detent. For example, detents can be provided in two ofchannels 244 on opposite sides of sleeve 206B. The remaining twochannels can simply include inclined surfaces with no detents.

Yet even another difference is that module 200B includes an alternatebiasing member 210B. Biasing member 210B is a compressible rubber ringthat exerts an upward force on the bottom of sleeve 206B, which isadapted to abut biasing member 210B. As shown in FIG. 9B, biasing member210B is an o-ring of substantially circular cross-section. However,alternate biasing members (e.g., die cut foam ring, rectangularcross-section, etc.) can be used.

Finally, it should be understood that the alternate features shown inmodule 200B are not necessarily dependent on one another. For example,module 200A could be modified to include four pins 234 without omittingswitch 216. As another example, wall 226B of module 200B could bemodified to define legs at the corners of the module (similar to module200A) instead of extending completely around sleeve 206B, therebyallowing a reduction in size. As yet another example, legs 228 of module200A can be extended upwardly to prevent external structures fromcontacting sleeve 206 or lens assembly 208. As these examples show, someof the alternate features of camera module 200B can be used independentof other features.

Various methods of the present invention will now be described withreference to FIGS. 10-13. For the sake of clear explanation, thesemethods are described with reference to the previously describedstructures. However, it should be noted that alternate structures,whether explicitly described herein or created in view of the presentdisclosure, could be substituted for those cited without departing fromthe scope of the present invention. Therefore, it should be understoodthat the methods of the present invention are not limited to anyparticular structures(s), unless explicitly recited in the claims.Further, some steps of the methods presented need not necessarily occurin the order shown. For example, in some cases two or more method stepsmay occur simultaneously. These and other variations of the methodsdisclosed herein will be readily apparent, especially in view of thedescription of the present invention provided previously herein, and areconsidered to be within the full scope of the invention.

FIG. 10 is a flow chart summarizing one method 1000 for assemblingcamera module 200 according to one aspect of the present invention. In afirst step 1002, substrate 212 with image capture device 214 mountedthereon is provided. Next, in a second step 1004, housing 204 is mountedon substrate 212, over image capture device 214. Then, in a third step1006, sleeve 206 is adjustably mounted to housing 210. Next, in a fourthstep 1008, lens assembly 208 is adjustably mounted in sleeve 206.Finally, in a fifth step 1010, lens assembly 208 is focused with respectto image capture device 214.

FIG. 11 is a flow chart summarizing one particular method 1100 formethod of performing third step 1006 (mount user adjustable carrier tohousing) of method 1000. In a first step 1102, biasing member 210 isprovided on housing 204. Next, in a second step 1104, sleeve 206 ispositioned to engage biasing member 210. Then, in a third step 1106,sleeve 206 is movably retained in housing 204 with retaining pins 234.Then, in a fourth step 1108, sleeve 206 is positioned to engage switch246, which serves as a position sensor for sleeve 206.

FIG. 12 is a flow chart summarizing one particular method 1200 forperforming fourth step 1008 (adjustably mount lens assembly to carrier)of method 1000. In a first step 1202, an adjustment feature (e.g.,thread set 248) is provided on the outer surface of lens assembly 208.Next, in a second step 1204, a complementary adjustment feature (e.g.,thread set 240) is provided on the inner surface of sleeve 208. Finally,in a third step 1206, the adjustment feature of lens assembly 208 isengaged with the complementary adjustment feature of sleeve 206 toadjustably mount lens assembly 208 to sleeve 206.

FIG. 13 is a flow chart summarizing one particular method 1300 forperforming fifth step 1010 (focus lens assembly with respect to imagecapturing device) of method 1000. In a first step 1302, sleeve 206 isrotated into one of the predefined user adjustable focal positions.Next, in a second step 1304, lens assembly 208 is rotated until it is infocus with respect to image capture device 214. Finally, in a third step1306, lens assembly 208 is permanently fixed in position within sleeve206.

The description of particular embodiments of the present invention isnow complete. Many of the described features may be substituted, alteredor omitted without departing from the scope of the invention. Forexample, alternate adjustment features may be substituted for theexample adjustment mechanisms provided. As another example, alternatebiasing members may be substituted for tapered ring 210 including, butnot limited to, resilient o-rings, die cut foam, and so on. These andother deviations from the particular embodiments shown will be apparentto those skilled in the art, particularly in view of the foregoingdisclosure.

1. A camera module comprising: a housing including a substantiallyrectangular base with side walls extending upwardly from said base, aportion of said side wall forming at least one leg extending upwardlyfrom at least one corner of said base; a lens assembly; and a carrierrotatably disposed within said housing, said carrier including a firstfocusing feature for adjustably engaging said lens assembly and a secondfocusing feature for adjustably engaging said housing, said carrierbeing a sleeve in the form of a substantially cylindrical shellincluding an inner wall, an outer wall, a top surface, and a bottomsurface.
 2. A camera module according to claim 1, wherein a portion ofsaid first focus feature is formed on said inner wall of said sleeve. 3.A camera module according to claim 2, wherein said first focus featureincludes a set of threads.
 4. A camera module according to claim 2,wherein said first focus feature includes at least one inclined surface.5. A camera module according to claim 2, wherein said first focusfeature includes a channel for engaging a protrusion.
 6. A camera moduleaccording to claim 1, wherein said outer wall of said sleeve includes aportion of said second focus feature.
 7. A camera module according toclaim 6, wherein said second focus feature includes at least one channeladapted to receive at least one pin.
 8. A camera module according toclaim 7, wherein said channel is formed in said sleeve and intersectssaid top surface or said bottom surface of said sleeve.
 9. A cameramodule according to claim 7, wherein said channel defines the rotationallimits of said sleeve.
 10. A camera module according to claim 7, whereinsaid channel defines at least two detents, each disposed to define aparticular focal length.
 11. A camera module according to claim 10,wherein said detents are spaced apart portions of said channel separatedby another portion of said channel that is relatively higher orrelatively lower than said spaced apart portions of said channel.
 12. Acamera module according to claim 10, wherein at least one of saiddetents provides a tactile indication of engagement or disengagement.13. A camera module according to claim 10, wherein said channel isformed on said sleeve and said pin is fixed to said housing.
 14. Acamera module according to claim 10, further comprising a biasing memberdisposed between said housing and said sleeve to bias a surface of saidchannel against said pin.
 15. A camera module according to claim 14,wherein said biasing member is a resilient ring disposed between saidbottom surface of said sleeve and said housing.
 16. A camera moduleaccording to claim 15, wherein said bottom portion of said sleeve istapered.
 17. A camera module according to claim 1, wherein said at leastone leg supports a guide pin of said second focus feature.
 18. A cameramodule according to claim 17, wherein at least one of said legs definesan aperture through which said guide pin is disposed.
 19. A cameramodule according to claim 17, wherein said housing includes a pluralityof said legs and a plurality of guide pins.
 20. A camera moduleaccording to claim 19, wherein each of said legs extend beyond a topsurface of said lens assembly.
 21. A camera module according to claim20, wherein each of said legs extend beyond said top surface of saidsleeve.
 22. A camera module according to claim 19, wherein at least twoof said legs are disposed on opposite corners of said housing.
 23. Acamera module according to claim 19, wherein an inner surface of saidleg is contoured to said sleeve.
 24. A camera module according to claim19, wherein an outer diameter of said sleeve is at least as large as thesmaller of the length or width of said rectangular base.
 25. A cameramodule according to claim 1, wherein an outer diameter of said sleeve isat least as large as the smaller of the length or width of saidrectangular base.
 26. A camera module according to claim 1, wherein saidhousing further includes at least one pin engaging said sleeve with saidhousing.
 27. A camera module according to claim 26, wherein said housingincludes a plurality of pins engaging said sleeve with said housing. 28.A camera module according to claim 27, wherein said housing includesexactly two pins.
 29. A camera module according to claim 27, whereinsaid housing includes exactly four pins.
 30. A camera module accordingto claim 27, wherein said pins are positioned at opposite corners ofsaid housing.
 31. A camera module according to claim 1, wherein saidhousing includes a rounded inner portion wherein said sleeve isdisposed.
 32. A camera module according to claim 1, wherein said base ofsaid housing defines an opening disposed such that light focused by saidlens assembly passes through said opening.
 33. A camera module accordingto claim 32, wherein said housing defines a channel around said openingto position a biasing member.
 34. A camera module according to claim 1,wherein said side walls extend beyond a top surface of said lensassembly.
 35. A camera module according to claim 1, wherein said sidewalls extend beyond said top surface of said sleeve.
 36. A camera moduleaccording to claim 1, wherein said camera module includes a biasingmember disposed between a portion of said housing and a portion of saidcarrier.
 37. A camera module according to claim 36, wherein said biasingmember is an o-ring.
 38. A camera module according to claim 36, whereinsaid biasing member is a resilient ring.
 39. A camera module accordingto claim 38, wherein said resilient ring is a compressible rubber ring.40. A camera module according to claim 38, wherein said resilient ringis tapered such that a diameter of an upper portion is larger than adiameter of a lower portion.
 41. A camera module according to claim 1,comprising: a substrate; and an image capture device fixed to saidsubstrate.
 42. A camera module according to claim 41, wherein saidcamera module further includes a switch operative to generate anelectrical signal based on one or more positions of said second focusfeature.
 43. A camera module according to claim 42, wherein said carrierincludes a portion disposed to actuate said switch.
 44. A camera moduleaccording to claim 42, wherein said housing encloses at least a portionof said switch.
 45. A camera module according to claim 41, wherein saidsubstrate is fixed to said housing.
 46. A camera module according toclaim 1, wherein said lens assembly is fixed in position with respect tosaid carrier.
 47. A camera module comprising: a housing; a lensassembly; a substrate; an image capture device fixed to said substrate;a carrier rotatably disposed within said housing, said carrier includinga first focusing feature for adjustably engaging said lens assembly anda second focusing feature for adjustably engaging said housing; and aswitch operative to generate an electrical signal based on one or morepositions of said second focus feature.
 48. A camera module according toclaim 47, wherein said carrier is a sleeve in the form of asubstantially cylindrical shell comprising: an inner wall; an outerwall; a top surface; and a bottom surface.
 49. A camera module accordingto claim 48, wherein a portion of said first focus feature is formed onsaid inner wall of said sleeve.
 50. A camera module according to claim49, wherein said first focus feature includes a set of threads.
 51. Acamera module according to claim 49, wherein said first focus featureincludes at least one inclined surface.
 52. A camera module according toclaim 49, wherein said first focus feature includes a channel forengaging a protrusion.
 53. A camera module according to claim 48,wherein said outer wall of said sleeve includes a portion of said secondfocus feature.
 54. A camera module according to claim 53, wherein saidsecond focus feature includes at least one channel adapted to receive atleast one pin.
 55. A camera module according to claim 54, wherein saidchannel is formed in said sleeve and intersects said top surface or saidbottom surface of said sleeve.
 56. A camera module according to claim54, wherein said channel defines the rotational limits of said sleeve.57. A camera module according to claim 54, wherein said channel definesat least two detents, each disposed to define a particular focal length.58. A camera module according to claim 57, wherein said detents arespaced apart portions of said channel separated by another portion ofsaid channel that is relatively higher or relatively lower than saidspaced apart portions of said channel.
 59. A camera module according toclaim 57, wherein at least one of said detents provides a tactileindication of engagement or disengagement.
 60. A camera module accordingto claim 57, wherein said channel is formed on said sleeve and said pinis fixed to said housing.
 61. A camera module according to claim 57,further comprising a biasing member disposed between said housing andsaid sleeve to bias a surface of said channel against said pin.
 62. Acamera module according to claim 61, wherein said biasing member is aresilient ring disposed between said bottom surface of said sleeve andsaid housing.
 63. A camera module according to claim 62, wherein saidbottom portion of said sleeve is tapered.
 64. A camera module accordingto claim 48, wherein said housing includes a substantially rectangularbase with side walls extending upwardly from said base.
 65. A cameramodule according to claim 64, wherein a portion of said side wall formsat least one leg extending upwardly from at least one corner of saidbase.
 66. A camera module according to claim 65, wherein said at leastone leg supports a guide pin of said second focus feature.
 67. A cameramodule according to claim 66, wherein at least one of said legs definesan aperture through which said guide pin is disposed.
 68. A cameramodule according to claim 66, wherein said housing includes a pluralityof said legs and a plurality of guide pins.
 69. A camera moduleaccording to claim 68, wherein each of said legs extend beyond a topsurface of said lens assembly.
 70. A camera module according to claim69, wherein each of said legs extend beyond said top surface of saidsleeve.
 71. A camera module according to claim 68, wherein at least twoof said legs are disposed on opposite corners of said housing.
 72. Acamera module according to claim 65, wherein an inner surface of saidleg is contoured to said sleeve.
 73. A camera module according to claim65, wherein an outer diameter of said sleeve is at least as large as thesmaller of the length or width of said rectangular base.
 74. A cameramodule according to claim 64, wherein an outer diameter of said sleeveis at least as large as the smaller of the length or width of saidrectangular base.
 75. A camera module according to claim 64, whereinsaid housing further includes at least one pin engaging said sleeve withsaid housing.
 76. A camera module according to claim 75, wherein saidhousing includes a plurality of pins engaging said sleeve with saidhousing.
 77. A camera module according to claim 76, wherein said housingincludes exactly two pins.
 78. A camera module according to claim 76,wherein said housing includes exactly four pins.
 79. A camera moduleaccording to claim 76, wherein said pins are positioned at oppositecorners of said housing.
 80. A camera module according to claim 64,wherein said housing includes a rounded inner portion wherein saidsleeve is disposed.
 81. A camera module according to claim 64, whereinsaid base of said housing defines an opening disposed such that lightfocused by said lens assembly passes through said opening.
 82. A cameramodule according to claim 81, wherein said housing defines a channelaround said aperture to position a biasing member.
 83. A camera moduleaccording to claim 64, wherein said side walls extend beyond a topsurface of said lens assembly.
 84. A camera module according to claim64, wherein said side walls extend beyond said top surface of saidsleeve.
 85. A camera module according to claim 47, wherein said cameramodule includes a biasing member disposed between a portion of saidhousing and a portion of said carrier.
 86. A camera module according toclaim 85, wherein said biasing member is an o-ring.
 87. A camera moduleaccording to claim 85, wherein said biasing member is a resilient ring.88. A camera module according to claim 87, wherein said resilient ringis a compressible rubber ring.
 89. A camera module according to claim87, wherein said resilient ring is tapered such that a diameter of anupper portion is larger than a diameter of a lower portion.
 90. A cameramodule according to claim 47, wherein said carrier includes a portiondisposed to actuate said switch.
 91. A camera module according to claim47, wherein said housing encloses at least a portion of said switch. 92.A camera module according to claim 47, wherein said substrate is fixedto said housing.
 93. A camera module according to claim 47, wherein saidlens assembly is fixed in position with respect to said carrier.